Company insight
Safe and efficient wind turbines for the future
With wind turbines constantly growing in size and power, manufacturers increasingly need the best equipment. World Wind Technology talks to Christian Beltoft at Pemamek to learn how the Finnish company’s sophisticated mix of welding technology, flange systems and turn-key approach can help the process stay efficient and safe.
tip heights expected to reach nearly 300m by the end of the decade – a future of mammoth constructions is edging into view. Clearly, this is good news for the environment. But from safety to cost, these colossal structures can also pose vast construction challenges. No wonder turbine manufacturers are rushing towards automated solutions, with one Finnish welding company offering the know-how to cut costs and keep workers safe. Few people know wind turbine construction like Christian Beltoft. He’s worked in the industry for years and, since October 2020, is the director of wind energy sales and development at Pemamek. As Beltoft explains, the rise of mammoth turbines is causing considerable headaches for manufacturers. “There’s a lot of plate joining coming up for customers,” he says, explaining that joining plates together is increasingly the only way to build big enough monopiles.
W A weld of difference
Of course, all this requires welding. But such thick, heavy plates require perfect precision – anything else risks fatally weakening the monopiles, with obvious financial and safety consequences. Fortunately, Pemamek has developed the Weldcontrol 500 system to automate the process. “We can preset the programming and the parameters before automating multipass welding,” Beltoft explains, adding that sophisticated scanning software can analyse the weld groove before and after welding.
That last point speaks to how cleverly Pemamek exploits data. The welder, after all, can use Weldcontrol 500 to see a graphical representation of the groove
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ind turbines are getting bigger. With blade lengths of 115m increasingly common – and
geometry on a screen. They can also explore other information, from fill volumes to temperatures to amperages. Apart from helping welders hone their technique, this means manufacturers can reassure partners about the quality of their craft. “It’s proof for their customers,” says Beltoft, “that the work is being done properly.”
position for welding. Given the weights involved, this process can unsurprisingly be dangerous, especially when massive cranes are introduced into the mix. Fortunately, Pemamek’s solution allows flanges to be fitted without turning the segment, liberating cranes for other tasks, reducing the risk of components getting damaged as
“From initial meetings and presentations, through yearly inspections and adjustments, it’s clear that Pemamek is a partner that takes the lifespan of its equipment seriously.”
Automation is bound to please customers in other ways too. Requiring fewer workers on-site, and dispensing with the cranes needed to reach out-the-way joints, Weldcontrol 500 is bound to cut costs and save time. Nor do Pemamek’s innovations end there. A particular focus involves induction-preheated welds. Apart from offering a faster time-to-temperature than traditional alternatives, this system also allows more sophisticated data analysis than would be possible with gas. As Beltoft explains, that potentially means welds could be heated to a lower temperature, once again saving time and energy. Combined with long stick-out technology (perfect for narrow grooves) and tiltable welding heads (boosting precision), it’s no wonder Beltoft is so enthusiastic about his company’s platform. As he puts it: “Automated welding is the way of the future.”
Keep a close eye on machinery The same could be said for Pemamek’s Flange Fitting Station. Historically, segments have first been flipped to horizontal fitting tables for the flanges to be fitted, then flipped back to their original
they’re moved, and cutting the fitting time to as little as two hours.
All this technical expertise is doubtless impressive. Yet it would mean little if it wasn’t shadowed by outstanding customer service. Yet here too, Beltoft and his colleagues show they understand their industry. Beltoft, for his part, describes working with customers holistically. “It’s a complete solution, because we do everything in house.” He means what he says. From initial meetings and presentations, through yearly inspections and adjustments, it’s clear that Pemamek is a partner that takes the lifespan of its equipment seriously.
More to the point, Beltoft obviously appreciates the economic necessity of keeping a close eye on Pemamek’s machinery. “If factories plan for production and something goes wrong, they’re behind and they can never catch up.” Given everything Pemamek offers, there’s little chance of that happening, even as turbines become bigger and the green revolution marches ever forward. ●
https://pemamek.com World Wind Technology /
www.worldwind-technology.com
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